Microneedle Mold Production Suppressing Step Formation
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Solution Overview
Problem
Existing methods for producing microneedle arrays face challenges such as the need for large master models, which increase production operations, and the formation of steps during the transfer of patterns to thermoplastic resins, leading to precision and productivity issues in microneedle arrays and electroforms.
Innovation Solution
A production method involving a plate precursor with a protruding pattern, aligned and pressed against a thermoplastic resin sheet, where the protrusions form a recessed pattern, and the process includes controlling the alignment and pressure to prevent step formation, using either a flat or depressed surface on the thermoplastic resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large master model is used to produce microneedle arrays, then the pattern coverage is sufficient, but the number of production operations increases
Solution Approach 1:
The invention divides the large master model into multiple small master models, each containing a portion of the microneedle array pattern. These small master models are produced separately and then transferred to the mold base in multiple operations, avoiding the need to produce one large master model that would require extensive operations.
2Ease of manufacture
If the flat surface of the mold is pressed against the thermoplastic resin, then the pattern transfer is simple, but steps are formed at the end portion of the mold
Solution Approach 1:
The invention modifies the mold surface by creating a depressed surface at the end portion where steps are likely to form. This localized modification ensures that the thermoplastic resin does not rise at the mold edges during pressing, preventing step formation while maintaining the simplicity of the pattern transfer process.
3Device complexity
If steps are formed at the mold end portion, then the mold structure is simple, but the precision and productivity of the duplicate mold or formed product deteriorate
Solution Approach 1:
The depressed surface is created only at the end portion of the mold where steps would form, rather than modifying the entire mold structure. This localized modification maintains the overall simplicity of the mold while preventing step formation that would compromise the precision of duplicate molds or formed products.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively suppresses the generation of steps at the end portions of recessed patterns, improving the precision and productivity of microneedle arrays and electroforms by reducing the number of operations and ensuring accurate pattern transfer.
Implementation Method 1
pressing the protrusions of the plate precursor which is heated against the thermoplastic resin sheet
Implementation Method 2
cooling the plate precursor in a state in which the pressed protrusions and the thermoplastic resin sheet are in contact with each other
Data Source
AI summary
A production method of a mold includes: preparing a plate precursor having a protruding pattern formed of protrusions in a pattern presence region on a base, and a thermoplastic resin sheet; determining a position at which the plate precursor is to be pressed against the thermoplastic resin sheet by moving the plate precursor and the thermoplastic resin sheet relative to each other; and forming a recessed pattern on the thermoplastic resin sheet by pressing the protrusions of the plate precursor which is heated against the thermoplastic resin sheet at a position where a part of the pattern presence region of the plate precursor excluding the protrusions is separated from a surface of the thermoplastic resin sheet, cooling the plate precursor in a state in where the pressed protrusions and the thermoplastic resin sheet are in contact with each other, and separating the plate precursor from the thermoplastic resin sheet.